Assembly

PROCEDURE

CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will cause bore distortion and binding of piston.

1. Clamp caliper in a vise with protective caps installed on jaws of vise..

Installing New Piston Seal In Caliper:

2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should be positioned at one area in groove and gently worked around the groove, using only your fingers until properly seated. NEVER USE AN OLD PISTON SEAL. Be sure that fingers are clean and seal is not twisted or rolled.
3. Coat new piston boot with clean brake fluid leaving a generous amount inside boot.
4. Position dust boot over piston after coating with brake fluid.

CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston in the bore of the caliper.

Installing Piston Into Caliper Bore:

5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore.
6. Position dust boot into the counterbore of the caliper assembly piston bore.





7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special Tool C-4171, or equivalent, drive boot into counterbore of the caliper.
8. Install guide pin sleeves and bushings. Refer to Guide Pin Installation.
9. Install brake pads. Refer to Disc Brake Pad Installation.
10. Before installing caliper assembly on vehicle, inspect brake rotor. If any conditions as described in Checking Brake Rotor for Runout and Thickness are present the rotor, must be replaced or refaced. If the rotor does not require any servicing, install caliper assembly.
11. Install brake hose onto caliper using banjo bolt. Torque the brake hose to caliper assembly banjo bolt to 33 Nm (24 ft. lbs). New seal washers MUST always be used when installing brake hose to caliper.
12. Bleed the brake system.